Output Shaft, Adjusting

Output Shaft, Adjusting

(Selecting the correct adjusting shim for the output shaft)

Special tools, testers and auxiliary items required

• Dial Gauge Holder (VW 387)

• Magnetic Plate 50 mm Dia. (VW 385/17)

• Thrust Pad (VW 512)

• Replacement Stud (8 mm/10 mm) (3114/2)

• Punch (VW 407)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Kukko Extractor 37-46 mm (21/6)

• Kukko Support (22/2)

• Dial Gauge

It is necessary to adjust the output shaft if the following components were replaced:

• Output shaft

• Clutch housing

or

• Tapered roller bearing

Adjustment overview. Refer to => [ Adjustment Overview ] Adjustment Overview.

Requirements:

• Remove any sealant still on the sealing surfaces on the clutch and transmission housings.

- Press the outer race/small tapered roller bearing with the adjustment shim 0.65 mm into the clutch housing as far as the stop. Refer to => [ Installing the Small Outer Race/Tapered Roller Bearing ] Output Shaft.

- Install the output shaft and tighten the bearing support nuts to 25 Nm + an additional 90° (1/4) turn.

- Rotate the output shaft 20 to 30 times in one direction.

• It must be rotated in one direction so the tapered roller bearing rollers are seated in one direction.

• Therefore, it must be rotated 20 to 30 times in one direction.

• Otherwise the measurements will be incorrect.

- Install the dial gauge (3 mm measuring range) and set to "0" with a 1 mm preload.






- Move the input shaft up and down, check the play on the dial gauge and make a note of it.

Determining Shim Thickness

The specified bearing tension is reached when the adjustment shim (0.65 mm) is added to the measured value.

Example:






Adjustment Shim Table






• For the correct shims, refer to the Parts Catalog.

- Remove the output shaft and then remove the small taper roller bearing outer race. Refer to => [ Remove the Small Outer Race/Tapered Roller Bearing ] Output Shaft.

- Install the shim with the correct thickness, thickest shim first.

• If the previous 0.65 mm adjustment shim will be inserted again, check it for damage.

If the measured shim thickness is larger than those listed in the table, then install two shims that add up to the necessary thickness.

Tolerance variations make it possible to find the exact shim thickness required.

- Press in small tapered roller bearing outer race with determined shim (0.70 mm as in example). Refer to => [ Installing the Small Outer Race/Tapered Roller Bearing ] Output Shaft and install output shaft. Tighten the bearing support nuts in the clutch housing to 25 Nm + an additional 90° (1/4) turn.